OK, I'm about at my wit's end trying to get this fault to stop appearing, so I'm going to throw it out to the hive mind and see if anyone has seen something similar.
This is going to be long because I've been dealing with it for months now. 2009 S5 4.2, 6MT. Drive Select (elect. suspension).
About 6 months ago I had an unrelated issue and scanned my car with VCDS and it returned hidden faults for the two front headlight level sensors, "implausible signal" on the right and "mechanical failure" on the left, both of which were very infrequently intermittent and dd not throw anything on the dash. Only saw them because I was in there looking for something else. So I got a couple cheap Chinese sensors off eBay and installed them. Passenger's side (the one with "implausible signal") went away and never returned, issue done. Immediately after startup the driver's side caused multiple different faults resulting in the car lighting up like a Christmas tree and screaming at me. Swapped sensors left-right, no change. Reinstalled old sensor, car seemed happy. Then I drove it, and now intermittently WHILE DRIVING ONLY I get BEEEEEEEEP "Suspension System Fault" and the yellow shock icon comes up until I restart the car. Then it goes away, and returns when I drive it again. Sometimes it'll go a long time without faulting, but every time I drive it I trigger it somehow, BEEEEEEEEEP. Mostly with the wheel turned left, or if I really goose the throttle so I assume when the weight is shifting OFF the left front tire.
OK, so seems pretty cut and dry that the sensor is bad, right? Except that I already tried 2 new senors there. Cheap Chinese ones, I get it. As luck would have it, the eBay company I bought them from sought some feedback and I reported back what was going on honestly. They graciously sent me 2 new sensors for free to try. So now I have 4 of them. None worked on the left front. The only thing that allowed me any driving time at all is reinstalling the original sensor. But even then, every time I drove it, BEEEEEEEEEEEEP at some random point during the drive.
All right, well, to be honest I didn't really like the way the plug seated on the new sensors. Maybe the contacts just weren't making. Now, I would have no problem dropping $150 on a new Audi branded sensor. But, I want to be clear, the way this is behaving I am NOT convinced that will fix the problem. I feel like I could go drop that $150 and I'm just throwing parts at a problem. So I bought a USED OEM sensor off eBay that was tested prior to removal. I figured, it might not be good, but the symptoms should CHANGE right? Even if it was bad, it should act differently in some way, right? Nope. Installed (theoretically good) used OEM sensor, and the problem behaved exactly the same.
Start it up, no issues, great, drive, at some point I will have to turn left or (God forbid) use the gas.
BEEEEEEEEEEEP. Suspension System Malfunction.
At exactly the same times as the first sensor.
OK, maybe the issue is the plug itself. Perhaps I routed the wire wrong and it's chafing, or getting tugged on when the control arm moves a certain way.
So I got back under there over the weekend, no chafing. Looks ok. Peeled back the rubber boot right on the plug itself and it was completely full of water. EUREKA! Yes! I've found it! The plug was full of water! OMGOMGOMG I'm so excited after MONTHS of BEEEEEEEEEEEEP I finally found the cause! Take plug apart, blow out with compressed air, dry with heat gun, pack boot with dielectric grease, reassemble. Back out of garage, run daughter up the block to her friend's house. Blissful silence. Return home. Taking the wife out tonight. Let's take my car, because I just saw Ford V. Ferrari today and I want to fucking drive. Back out of the driveway into the street and....you guessed it.....
BEEEEEEEEEEEEP.
Oh screw you.
So here's where I am:
4 cheap Chinese sensors do not work AT ALL. The car will not recognize them in any way.
2 used OEM sensors (the original one for the car, and a second one I bought) work MOST of the time. However there is a specific way the suspension moves that will trigger the fault. BOTH sensors behave in EXACTLY the same way, which is why I have not just gone and bought a NEW OEM sensor. I am not convinced this is the problem, but if you guys can convince me otherwise I would be THRILLED to go get a new OEM sensor.
This is ONLY on the left front. Nothing from any other position. The fault is always the same. Here is a cut and paste of the VCDS logfile:
Address 14: Susp. Elect. (J250) Labels: None
Part No SW: 8K0 907 364 HW: 8K0 907 364
Component: DAEMPFUNGS-SG H08 0052
Revision: 00000000 Serial number: 18110803630002
Coding: 050181
Shop #: WSC 01122 444 53808
VCID: 70B9D379DAA5FB276E5-8024
2 Faults Found:
00776 - Level Control System Sensor; Left Front (G78)
003 - Mechanical Failure - Intermittent
Freeze Frame:
Fault Status: 00100011
Fault Priority: 2
Fault Frequency: 18
Reset counter: 81
Mileage: 101407 km
Time Indication: 0
The 2nd fault of the "2 faults found" is just that odd "comfort restriction" that goes along with the level sensor fault.
The "MEchanical Failure" really has me stumped. It's not even listed as a possibility in the VCDS Wiki.
Please help. I am pulling my hair out over this, but I am not about to just throw parts at it without knowing damn well where the fault is, and based on the fact that 2 completely different OEM sensors behave in exactly the same way, I'm not convinced buying a third will solve the issue.
Is it possible the electric strut is actually the culprit, masquerading as a HL level sensor?
So at this point I don't know what else to do. I guess I'll order a new sensor. Can you guys just confirm a couple stupid obvious questions, so I can make sure I haven't been barking up the wrong tree for six months now?
1. The fault I am getting is "00776 - Level Control System Sensor; Left Front (G78)". First off, am I even looking at the right sensor? I have been futzing with the sensor that has the green bellcrank with the little silver arm that goes to the lower control arm. Is there any chance I'm looking at the wrong thing? My strut has a small electrical plug on it. Is there any chance this is another sensor and is really the one that's been causing my issue? Or is that the input for the dynamic ride to the damper?
2. When I go into VCDS (under 55-Headlight Range, under anything suspension related, the individual values box was grayed out) to look at the real-time values, I'm only offered front and rear. I know for a fact that all four corners have one of these bellcrank sensors. Why can't I read them out individually? Are they combining two sensors to give me a front and a rear height or something? Or am I looking at the wrong thing?
3. REALLY stupid question - "Left" sensor IS actually referring to the driver's side in the U.S., right? Just want to make sure Audi didn't decide to label the sides based on the mechanic loong at the front of the vehicle or something. Which would be ridiculous, but hey, I'm dying here. BEEEEEEEEEEEEEEP.
4. Can someone please detail exactly how to calibrate these sensors, so I know I'm doing it right? I have been doing the following:
- 55-Headlight Range
- Go to the drop-down menu about halfway down the box and select the only option available in it, something like "calibrate and adjust". Can't recall exact verbiage and I'm not outside plugged into the car right now to check.
- At this point the boxes across the top say "waiting", click "NEXT"
- Boxes change to "adjust" "headlights", waiting for me to make physical adjustments, which I don't need, so again I just click "NEXT".
- At this point I get some sort of tag that says calibration complete or something. When I check the real-time readouts for the front and rear sensors, sure enough wherever they were, they now change to 0.
Is that it, or is there some other initialization I need to make when I install a new sensor?
Please help! Thanks!
Darel
This is going to be long because I've been dealing with it for months now. 2009 S5 4.2, 6MT. Drive Select (elect. suspension).
About 6 months ago I had an unrelated issue and scanned my car with VCDS and it returned hidden faults for the two front headlight level sensors, "implausible signal" on the right and "mechanical failure" on the left, both of which were very infrequently intermittent and dd not throw anything on the dash. Only saw them because I was in there looking for something else. So I got a couple cheap Chinese sensors off eBay and installed them. Passenger's side (the one with "implausible signal") went away and never returned, issue done. Immediately after startup the driver's side caused multiple different faults resulting in the car lighting up like a Christmas tree and screaming at me. Swapped sensors left-right, no change. Reinstalled old sensor, car seemed happy. Then I drove it, and now intermittently WHILE DRIVING ONLY I get BEEEEEEEEP "Suspension System Fault" and the yellow shock icon comes up until I restart the car. Then it goes away, and returns when I drive it again. Sometimes it'll go a long time without faulting, but every time I drive it I trigger it somehow, BEEEEEEEEEP. Mostly with the wheel turned left, or if I really goose the throttle so I assume when the weight is shifting OFF the left front tire.
OK, so seems pretty cut and dry that the sensor is bad, right? Except that I already tried 2 new senors there. Cheap Chinese ones, I get it. As luck would have it, the eBay company I bought them from sought some feedback and I reported back what was going on honestly. They graciously sent me 2 new sensors for free to try. So now I have 4 of them. None worked on the left front. The only thing that allowed me any driving time at all is reinstalling the original sensor. But even then, every time I drove it, BEEEEEEEEEEEEP at some random point during the drive.
All right, well, to be honest I didn't really like the way the plug seated on the new sensors. Maybe the contacts just weren't making. Now, I would have no problem dropping $150 on a new Audi branded sensor. But, I want to be clear, the way this is behaving I am NOT convinced that will fix the problem. I feel like I could go drop that $150 and I'm just throwing parts at a problem. So I bought a USED OEM sensor off eBay that was tested prior to removal. I figured, it might not be good, but the symptoms should CHANGE right? Even if it was bad, it should act differently in some way, right? Nope. Installed (theoretically good) used OEM sensor, and the problem behaved exactly the same.
Start it up, no issues, great, drive, at some point I will have to turn left or (God forbid) use the gas.
BEEEEEEEEEEEP. Suspension System Malfunction.
At exactly the same times as the first sensor.
OK, maybe the issue is the plug itself. Perhaps I routed the wire wrong and it's chafing, or getting tugged on when the control arm moves a certain way.
So I got back under there over the weekend, no chafing. Looks ok. Peeled back the rubber boot right on the plug itself and it was completely full of water. EUREKA! Yes! I've found it! The plug was full of water! OMGOMGOMG I'm so excited after MONTHS of BEEEEEEEEEEEEP I finally found the cause! Take plug apart, blow out with compressed air, dry with heat gun, pack boot with dielectric grease, reassemble. Back out of garage, run daughter up the block to her friend's house. Blissful silence. Return home. Taking the wife out tonight. Let's take my car, because I just saw Ford V. Ferrari today and I want to fucking drive. Back out of the driveway into the street and....you guessed it.....
BEEEEEEEEEEEEP.
Oh screw you.
So here's where I am:
4 cheap Chinese sensors do not work AT ALL. The car will not recognize them in any way.
2 used OEM sensors (the original one for the car, and a second one I bought) work MOST of the time. However there is a specific way the suspension moves that will trigger the fault. BOTH sensors behave in EXACTLY the same way, which is why I have not just gone and bought a NEW OEM sensor. I am not convinced this is the problem, but if you guys can convince me otherwise I would be THRILLED to go get a new OEM sensor.
This is ONLY on the left front. Nothing from any other position. The fault is always the same. Here is a cut and paste of the VCDS logfile:
Address 14: Susp. Elect. (J250) Labels: None
Part No SW: 8K0 907 364 HW: 8K0 907 364
Component: DAEMPFUNGS-SG H08 0052
Revision: 00000000 Serial number: 18110803630002
Coding: 050181
Shop #: WSC 01122 444 53808
VCID: 70B9D379DAA5FB276E5-8024
2 Faults Found:
00776 - Level Control System Sensor; Left Front (G78)
003 - Mechanical Failure - Intermittent
Freeze Frame:
Fault Status: 00100011
Fault Priority: 2
Fault Frequency: 18
Reset counter: 81
Mileage: 101407 km
Time Indication: 0
The 2nd fault of the "2 faults found" is just that odd "comfort restriction" that goes along with the level sensor fault.
The "MEchanical Failure" really has me stumped. It's not even listed as a possibility in the VCDS Wiki.
Please help. I am pulling my hair out over this, but I am not about to just throw parts at it without knowing damn well where the fault is, and based on the fact that 2 completely different OEM sensors behave in exactly the same way, I'm not convinced buying a third will solve the issue.
Is it possible the electric strut is actually the culprit, masquerading as a HL level sensor?
So at this point I don't know what else to do. I guess I'll order a new sensor. Can you guys just confirm a couple stupid obvious questions, so I can make sure I haven't been barking up the wrong tree for six months now?
1. The fault I am getting is "00776 - Level Control System Sensor; Left Front (G78)". First off, am I even looking at the right sensor? I have been futzing with the sensor that has the green bellcrank with the little silver arm that goes to the lower control arm. Is there any chance I'm looking at the wrong thing? My strut has a small electrical plug on it. Is there any chance this is another sensor and is really the one that's been causing my issue? Or is that the input for the dynamic ride to the damper?
2. When I go into VCDS (under 55-Headlight Range, under anything suspension related, the individual values box was grayed out) to look at the real-time values, I'm only offered front and rear. I know for a fact that all four corners have one of these bellcrank sensors. Why can't I read them out individually? Are they combining two sensors to give me a front and a rear height or something? Or am I looking at the wrong thing?
3. REALLY stupid question - "Left" sensor IS actually referring to the driver's side in the U.S., right? Just want to make sure Audi didn't decide to label the sides based on the mechanic loong at the front of the vehicle or something. Which would be ridiculous, but hey, I'm dying here. BEEEEEEEEEEEEEEP.
4. Can someone please detail exactly how to calibrate these sensors, so I know I'm doing it right? I have been doing the following:
- 55-Headlight Range
- Go to the drop-down menu about halfway down the box and select the only option available in it, something like "calibrate and adjust". Can't recall exact verbiage and I'm not outside plugged into the car right now to check.
- At this point the boxes across the top say "waiting", click "NEXT"
- Boxes change to "adjust" "headlights", waiting for me to make physical adjustments, which I don't need, so again I just click "NEXT".
- At this point I get some sort of tag that says calibration complete or something. When I check the real-time readouts for the front and rear sensors, sure enough wherever they were, they now change to 0.
Is that it, or is there some other initialization I need to make when I install a new sensor?
Please help! Thanks!
Darel
